D5 (94J) Generator issues

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kharville

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[attachment=59162]Screenshot_2020-06-04-21-48-17.jpg[/attachment][attachment=59163]20200608_172243_2_2.jpg[/attachment]

Hi all. I have been trying to figure out why my batteries were not holding. Turns out that I get negative reading when I hit the glow plugs and nothing on the gauge when running. Hence, no charge. I pasted the wiring diagram I am using along with my regulator. Nothing is labeled and every wire is blue. Troubleshooting steps mention terminals Batt, A, F and G. I think I found Batt which has 24v present. The other 2 terminals on that side of the regulator along with the single wire on the other side test as dead short to ground. Is there a way to tell what is A and F on the generstor?
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Tue, Jun 9, 2020 9:19 AM

neil

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On my 5U, I had to carefully clean the regulator terminals and I found A, F, and something else stamped into the terminals. It was the same on the generator, so that might work for you. Wire brush and then a little sandpaper and then wipe with your finger to highlight any markings

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Tue, Jun 9, 2020 9:53 PM

ccjersey

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Bat is 1
Arm/GEN is 2
FLD is 3
Ground is 4-5 bypassing the rubber isolators

Have you polarized the generator?

Neil is right. If you remove the screws and clips holding the wires on, the terminals on the regulator are stamped. Never a bad idea to clean all connections.

D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄

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Tue, Jun 9, 2020 9:55 PM

kharville

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Reply to ccjersey:

Bat is 1
Arm/GEN is 2
FLD is 3
Ground is 4-5 bypassing the rubber isolators

Have you polarized the generator?

Neil is right. If you remove the screws and clips holding the wires on, the terminals on the regulator are stamped. Never a bad idea to clean all connections.

[quote="ccjersey"]Bat is 1
Arm/GEN is 2
FLD is 3
Ground is 4-5 bypassing the rubber isolators

Have you polarized the generator?

Neil is right. If you remove the screws and clips holding the wires on, the terminals on the regulator are stamped. Never a bad idea to clean all connections.[/quote]

I plan on cleaning it up good. I assume to polarize I touch batt to arm briefly?

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Wed, Jun 10, 2020 2:04 AM

ccjersey

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That’s the usual procedure for DELCO units.

D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄

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Thu, Jun 11, 2020 3:49 AM

kharville

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Reply to ccjersey:

That’s the usual procedure for DELCO units.

I got it off and cleaned it. Terminals are indeed stamped. Under the cover looked perfect. What's the importance of the regulator being suspended by rubber? The little rubber bushings are gone. With a ground wire coming out the back is the little frayed ground wire needed also?
[attachment=59192]20200612_182925.jpg[/attachment]

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Sat, Jun 13, 2020 7:01 AM

Old Magnet

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Reply to kharville:

I got it off and cleaned it. Terminals are indeed stamped. Under the cover looked perfect. What's the importance of the regulator being suspended by rubber? The little rubber bushings are gone. With a ground wire coming out the back is the little frayed ground wire needed also?
[attachment=59192]20200612_182925.jpg[/attachment]

Purpose of the rubber mounting is to eliminate shock and reduce vibration.
https://brillman.com/product/regulator-shock-mount-kit/

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Sat, Jun 13, 2020 7:13 AM

ccjersey

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Yes ground wire is needed too.

The vibration is why the regulator is almost never mounted directly on the engine or generator itself. The regulators inside vibrate as part of their normal function, external vibration can’t help!

D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄

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Sat, Jun 13, 2020 10:05 PM

kharville

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Reply to ccjersey:

Yes ground wire is needed too.

The vibration is why the regulator is almost never mounted directly on the engine or generator itself. The regulators inside vibrate as part of their normal function, external vibration can’t help!

[quote="ccjersey"]Yes ground wire is needed too.

The vibration is why the regulator is almost never mounted directly on the engine or generator itself. The regulators inside vibrate as part of their normal function, external vibration can’t help![/quote]

I got the regulator mounted again on the rubber isolation pads. Before I connected everything I wanted to check the Arm and Field wires from regulator to generator. I found all terminals had a short to ground. I then proceeded to the generator to find the ARM and FLD terminals grounded there also. Disconnecting the wires indicated no short to ground in the wires. In short I have the generator off now and it shows continuity across all 3 generator terminals. I guess I need to open it up as that doesn't sound right.

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Wed, Jun 17, 2020 9:25 AM

D6c76a

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Reply to kharville:

[quote="ccjersey"]Yes ground wire is needed too.

The vibration is why the regulator is almost never mounted directly on the engine or generator itself. The regulators inside vibrate as part of their normal function, external vibration can’t help![/quote]

I got the regulator mounted again on the rubber isolation pads. Before I connected everything I wanted to check the Arm and Field wires from regulator to generator. I found all terminals had a short to ground. I then proceeded to the generator to find the ARM and FLD terminals grounded there also. Disconnecting the wires indicated no short to ground in the wires. In short I have the generator off now and it shows continuity across all 3 generator terminals. I guess I need to open it up as that doesn't sound right.

The simple solution would be to put a gm 1 wire alternator on her. What I did with d5 98j 525. Working like a champ.

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Wed, Jun 17, 2020 9:36 AM

ccjersey

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The generator has a grounded brush on the armature AND the field on your unit is connected to the ARM/GEN/positive brush. So, it will always show continuity to ground. Resistance back through the field terminal should be higher than the ARM terminal tested to the frame, but it’s still going to be low. Lift the grounded brush off the commutator and slip a piece of paper under it before testing for shorts.

D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄

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Wed, Jun 17, 2020 8:44 PM

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